Electrical Automatic Control Circuit Assembly, Adjustment, Maintenance, and Assessment Equipment 5563SA62 electrical training equipment

I. Product Overview
This device combines current developments in industrial electrical automation application technology and device technology in my country, fully considering practicality and advanced features. The device adopts a modular structure, with training modules including a PLC main unit module, frequency converter module, touch screen module, servo control module, physical control model, simulated load module, and a variety of verification and demonstration devices. Training content includes basic PLC training, comprehensive PLC training, frequency converter recognition, operation, parameter setting, and communication training, touch screen recognition, operation, and application training, servo control training, network interface expansion, data acquisition, data display, keyboard control, timers, and interface training, etc. The training projects are rich, comprehensive, and keep pace with the development trends of industrial automation.

II. Product Features

1. Modular structure, easy module replacement, convenient for organizing various training projects and expanding new training functions.

2. Suitable for pre-employment and pre-job comprehensive skills training, suitable for advanced worker skills training and assessment.

3. Capable of designing, selecting, installing, debugging, and simulating small-scale engineering projects.

4. Requires only a three-phase four-wire AC power supply. Offers abundant and comprehensive training resources, effectively saving on training space.

5. High safety: In addition to voltage-type and current-type leakage protectors, the device features overload or short-circuit soft-cutoff protection with full microcontroller monitoring, ensuring equipment and personnel safety.

III. Equipment Features

1. The training system is designed for one-time construction. This equipment uses a universal wide-port design, allowing all host I/O ports to be brought out via opto-isolation adapters (protecting host components). It can be used for plug-in training or wired practical training.

2. The host uses the S7-1200 series PLC, comprehensively covering commonly used Siemens PLC types. The host can be connected to the training area via parallel port for practical training. The learning approach, from simple to complex, makes it easy for students to understand and learn.

3. Adopting a modular structure, it includes digital input/output, analog input/output, frequency converter, touchscreen, and communication modules, along with MCGS industrial control configuration and monitoring software, to achieve simulation-based and information-based practical training.

4. Project training module: Utilizing typical programmable logic controllers (PLCs) and bus technology, it enables the control of logic, simulation, processes, and motion in simulated objects and physical models of typical industrial production cases.

5. Understand the structure and characteristics of PLC Ethernet communication and Profinet bus communication;

6. Understand the usage of PLC digital input/output modules and analog input/output modules;

7. Master the basic programming methods of PLCs and be proficient in using basic programming languages;

8. Master the configuration programming methods of touch screens;

9. Master the communication between PLCs, frequency converters, and touch screens;

10. Be proficient in using PLCs and various electrical components to build PLC control systems;

11. Be proficient in using PLCs and simulated physical control objects to build various complex control systems;

12. Be proficient in completing Ethernet communication test experiments between PLCs;

13. Be proficient in completing frequency converter debugging and control experiments using PLCs and frequency converters via Profinet bus;

14. Master the use of PLC practical training course APP software; IV. Configuration List of Electrical Automatic Control Circuit Assembly, Adjustment, and Maintenance Assessment Platform Equipment Platform Configuration:
1. The main frame of the equipment is constructed from high-quality 128mm×34mm±1mm industrial aluminum profiles. The equipment layout area uses standard perforated plates made of 1.5mm thick high-quality steel plates precision-machined by CNC machining. The surface is treated with acid pickling and phosphating, followed by high-temperature electrostatic powder coating.

2. The equipment is equipped with wheels for easy movement and placement.

3. Dimensions: ≥W1200*D700*H1800mm
Power Supply Box (Can be used independently without the experimental platform)

Configuration:

4. AC Output: Three-phase five-wire AC 380V±10%; Single-phase three-wire AC 220V±10%. Power is switched on and off using an automatic air switch, equipped with short-circuit protection, leakage protection, grounding protection, and emergency stop protection.

5. DC Regulated Power Supply: DC24V/2A or higher, adjustment accuracy 1%, with short-circuit soft current limiting and short-circuit self-recovery functions.

6. The intelligent power supply protector features protection against phase loss, undervoltage, overvoltage, leakage current, overcurrent, short circuit, and surge, and has an automatic reclosing function;

7. The leakage current protection setting range is adjustable, and the leakage current protection action time is no more than 0.1s;

8. The overvoltage protection range is adjustable, and the overvoltage protection action time is no more than 5s;

9. The overcurrent protection range is adjustable, and the overcurrent protection action time is no more than 5s; the short circuit protection circuit is three times the rated circuit, and the overcurrent protection action time is no more than 0.1s;

10. The protection device has lightning protection function. 11. A 2KV high-voltage pulse test between L and N does not produce false tripping;

12. Fault information can be stored for no less than 999 entries;

13. Both operating and fault status are indicated by indicator lights, displaying real-time voltage, current, leakage current, and other parameters, with audible and visual alarm functions;

14. Parameter modification and setting buttons facilitate on-site modification of protection parameters; remote DI and DO functions are available for remote power supply control and power control cabinet door opening detection alarm; the main control unit can have an RS485 interface for multi-device connection and communication.

15. The equipment supports cloud system remote monitoring, allowing viewing of remote real-time data, data curve display, online setting of protection parameters, and remote control of power on/off. It is equipped with a wireless/wired control module, allowing monitoring of the power supply via monitoring software and power-off/start control of the equipment. Four input channels can control relay operation. Control Module I

Configuration:
15. PLC: Siemens S7-1200 series main unit, CPU 1214C, compact CPU, DC/DC/DC, Onboard I/O: 14 24V DC digital inputs; 10 24V DC digital outputs; 2 AI 0-10V DC, Power supply: DC 20.4-28.8V, Program/Data memory 100 KB; Digital expansion I/O: 16 DI/16 DO, 16DI/16DO, 16DI 24V DC, sink/source current, 16DO, 2A relays.

16. Frequency Inverter: Employs a Siemens G120C frequency inverter, equipped with integrated safety features including STO, PROFINET 6DI, 3DO, 2AI, 2AO, maximum 1F-DI PTC/KTY interface, USB and SD/MMC interfaces, IP20 protection rating, light load power: 0.55KW, heavy load power: 0.37KW.

17. Servo System: Utilizes a Siemens V90 series servo controller and servo motor, input voltage: 200-240V single-phase AC -15%/+10% 5.0A/3.0A 45-66, capable of internal positioning block function, and also features pulse position control, speed control, and torque control modes.

18. Touch Screen: Employs a Siemens KTP700 series touch screen, button/touch operation, 7″ TFT display, 65536 Color, PROFINET interface.

19. Stepper Driver Module: Two-phase stepper motor driver, rated current range 1.0-4.2A, power supply voltage DC18-48V, microstepping 1-128, pulse control type.

Control Module II (can be used independently without the experimental platform)

Configuration:
20. Main structure is a 3mm aluminum alloy cuboid, including multiple intermediate relays, indicator lights, buttons, etc.

21. Control circuit uses spring-loaded terminals.
Electrical Automatic Control Circuit Assembly, Adjustment, Maintenance, and Assessment Device
Sorting Task Module

Configuration:
22. Function: Module The proposed production line is automated, with frequency converters controlling the conveyor motors for speed regulation. Multiple sensors, including fiber optic, photoelectric, metal, and RFID sensors, are used for detection. A PLC controls servo motors, stepper motors, and various cylinders to perform multiple functions.

23. Structure: The model’s base plate is made of 20mm thick anodized aluminum plate, equipped with four black cast aluminum handles for easy handling. Above the base plate are a circular conveyor belt, pneumatic manipulator, handling gantry, sorting mechanism, frequency converter motors, servo motors, stepper motors, various sensors, and cylinders.

24. Main Components:

1. Three-phase AC geared motor

1) 1. **Servo Motor**
1) **Operating Voltage:** 380V
2) **Power:** 25W
3) **Reduction Ratio:** 1:50
2. **Servo Motor**
1) **Operating Voltage:** 230V 3AC
2) **PN =** 0.1kW
3) **NN =** 3000rpm
4) **M0 =** 0.32Nm
5) **MN =** 0.32Nm
6) **Shaft Height:** 20mm
7) **Incremental Encoder TTL:** 2500 increments/revolution
8) **Protection Rating:** IP65
3. **Stepper Motor**
1) **Rated Voltage:** 3V
2) **Rated Current:** 2A
3) **Step Angle:** 1.8°
4) **Motor Length:** 49mm
5) **Holding Torque:** 0.48N.m
6) **Number of Motor Wires:** 4 wires
7) **Step Accuracy:** 5%
8) **Insulation Resistance:** 100MΩ Min 500VDC
9) **Withstand Voltage:** 500V AC 1 minute

10) Radial runout: Maximum 0.02mm (450g load)

11) Axial runout: Maximum 0.08mm (450g load)

4. Industrial RFID Reader

1) Supports up to 1.5W RF power;

2) Sensing distance up to 20cm

3) Length: 82mm;

4) Front diameter: 32mm;

5) Adjustable distance outer diameter: 35/38mm;

6) Cable length: 1500mm;

DC Speed ​​Control Module

Configuration:
25. The DC speed control module uses a tachogenerator feedback voltage and a given voltage to form a closed-loop speed control system. The speed control system consists of a given voltage, speed negative feedback, an amplifier circuit, a trigger generation circuit, and a main circuit. It requires a digital display system and a transparent protective cover.

26. The DC speed control PCB board adopts a plug-in design for easy removal by trainees. Trainees perform measurement and analysis according to functional requirements, and complete fault diagnosis and troubleshooting.

Motor Set Module Configuration: Includes stepper motor, servo motor, and AC motor.

Computer Desk
Configuration:
28. Function: Industrial aluminum profile frame structure, single workstation, equipped with computer host and keyboard bracket for placing programming computer.

29. Dimensions: Not less than L600mm × W700mm × H780mm
30. Desk Body: The desk body is equipped with casters with brakes for easy movement and fixing.

Assembly Table (Anti-static Assembly Platform)
Configuration:
31. Function: Composed of desk body, tool cabinet, and worktop, used for assembling electrical and mechanical structures.

32. Dimensions: Not less than L600mm × W700mm × H780mm Less than L1500mm × W700mm × H780mm

33. Table Body: The assembly table has a pre-installed power socket expansion hole, which can be added as needed. The entire assembly table can be easily disassembled for convenient transportation and installation.

34. Tool Cabinet: Made of cold-rolled steel plate, bent and welded, the tool cabinet has multiple drawers for storing tools and is placed on one side of the bottom of the assembly table.

35. Tabletop: Made of 50mm thick high-pressure composite molded fiberboard, the surface is covered with 2mm green anti-static rubber, and the four sides are reinforced with 5mm… PVC cross-section edge sealing, the tabletop has the characteristics of wear resistance, heat resistance, stain resistance and easy cleaning. It has the functions of impact resistance, acid and alkali resistance, shock absorption and anti-static.

Electrical automatic control circuit assembly, adjustment and maintenance assessment device main assessment content

Configuration:

38. Main assessment content:

(1) Touch screen engineering creation, editing and download operation

(2) Touch screen offline simulation application

(3) Touch screen animation element application

(4) Touch screen numerical and text input display element application

(5) Touch screen system comprehensive application

(6) Stepper motor driver wiring and debugging

(7) Stepper motor driver parameter setting

(8) Stepper motor driver and PLC pulse positioning control

(9) Servo motor driver wiring Debugging

(10) Setting servo motor driver parameters

(11) Pulse positioning control between servo motor driver and PLC

(12) Communication positioning control between servo motor driver and PLC

(13) PLC and RFID communication reading and writing programming debugging

(14) Wiring and debugging of motor controlled by frequency converter

(15) Setting frequency converter parameters

(16) Multi-speed operation of ring conveyor sorting task model controlled by frequency converter

(17) Communication operation between PLC and frequency converter

(18) Wiring and debugging of sorting task model

(19) Sorting task model operation control program design

(20) Comprehensive application training of PLC, touch screen, frequency converter and servo system

(21) Checking the composition of dual closed-loop DC speed regulation system Dual Closed-Loop DC Speed ​​Control System Debugging and Analysis
Tools and Instruments
Configuration:
39. Supporting Equipment
(1) Special Screwdriver: 1 for use with spring terminals
(2) Large Dual-Purpose Screwdriver 6-inch 1
(3) Small Dual-Purpose Screwdriver 1
(4) Ratchet-Type Cold-Pressure Terminal Pliers 1
(5) Hex Socket Head Caps, Medium-Length, 9-Piece Set 1 Set
(6) Wire Peeling Pliers 6-inch 1
(7) Needle-Nose Pliers 6-inch 1
(8) Tool Box 10-inch 1
(9) Multimeter UT39A+ 1
(10) Thickened Safety Helmet 1
(11) Cable Relay Tool, 5 Types of Wires 1 Set
(12) Bench Vise, Bench Vise Jaw Width Should Be Greater Than 75mm (Do Not Drill Holes for Installation) 1
(13) Small Air Compressor 24L-750W 1 set

(14) Matching wires, air hoses and connecting accessories, provided according to actual needs